Method of making an absorbent article having leg cuffs combined with containment flaps

ABSTRACT

The invention relates to methods of fabricating an absorbent article. In one method of the invention, combination containment flaps and leg cuffs are formed on a common substrate. A plurality of elastomeric elements are included in the combination article to assist in forming containment flaps. Discrete leg cuff pieces are applied to the substrate at longitudinally spaced locations. In some embodiments, a cutting device slits the substrate substantially along a center line extending the length of the substrate, forming two continuous substrate portions. A glue gun applies adhesive to the substrate portion. The substrate portions are folded lengthwise, using the adhesive to form integral containment flaps and leg cuffs in a composite substrate. The composite substrate is secured to an absorbent article web sausage in forming absorbent articles. In another embodiment, the substrate is a first substrate which supports elastomeric elements used in forming leg cuffs and containment flaps. The first substrate is secured to a second substrate, thus forming a base structure, with the elastomeric elements between the first and second substrates. A bodyside liner and an absorbent core are added on one side of the base structure, and an outer cover is added on the second side, to form a web sausage. In both embodiments the web sausage is cut transversely at spaced locations along the length of the web sausage, to form absorbent articles.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of Ser. No. 08/777,685filed Dec. 20, 1996, now U.S. Pat. No. 5,827,387.

FIELD OF THE INVENTION

The present invention relates to methods for fabricating absorbentarticles. Such methods usually include gluing and may include ultrasonicbonding, to combine elements and form absorbent articles.

BACKGROUND OF THE INVENTION

Conventional methods of making absorbent articles, such as disposablediapers, are well known in the art. These methods usually rely onattaching leg cuffs, containment flaps, and other elements to theabsorbent article as continuous webs of attachment material. Thus acontinuous strip of material, such as leg cuff material, is continuouslyapplied to the shell of an absorbent article. This method allows forhigh speed forming of absorbent articles.

Applicants' process greatly reduces the complexity by placing leg cuffsand containment flap elastomeric elements on a continuous web orsubstrate. The continuous web is slit and folded to create two combinedleg cuffs and containment flaps, and is then secured to an absorbentarticle web sausage.

By forming the leg cuffs and containment flaps separately from the websausage, the number of processing steps or operations to the web sausageis reduced. This can increase the throughput speed of the manufacturingprocess.

Another of applicants' methods forms the combined leg cuff andcontainment flaps on a substrate and then secures an outer cover to afirst side of the substrate and a bodyside liner and absorbent core to asecond side of the substrate, thus forming a further unique absorbentarticle.

SUMMARY OF THE DISCLOSURE

The present invention relates to methods for fabricating absorbentarticles, and focuses on forming leg cuffs and containment flaps. Moreparticularly, the methods include applying elastomeric elements to acontinuous web substrate and applying leg cuffs at longitudinally spacedlocations along the substrate. The leg cuffs are transversely spacedfrom the elastomeric elements. One method further includes slitting thecontinuous web along its length at a center line to form two continuousweb substrate portions, each having the leg cuffs and the elastomericelements. The two continuous web portions are folded to form respectivecomposite substrates of containment flap material, with leg cuffs spacedalong the length of the containment flap material. The integral legcuffs and containment flaps are then applied to a web sausage.

In one embodiment, opposed pairs of leg cuff pieces are longitudinallyspaced along the length of each of the respective composite substrates.The opposed pairs of leg cuff pieces are disposed between the outeredges of the respective composite substrates and longitudinallyextending elastomeric elements on the respective composite substrate.

In another embodiment the extensible leg cuffs are stretched, preferablyto a dimension representing about 20% to 50% of the respectivestretch-to-stop distance, when secured to the substrate.

In yet another embodiment, the leg cuff pieces comprise elastomericstrands secured to a generally nonelastomeric piece of material.

In still another embodiment, the leg cuff pieces, when secured to thesubstrate, substantially cover the leg cut-outs.

Another embodiment includes the step of applying ultrasonic energy tothe respective composite substrates to finish and smooth raw edgesthereon.

In a further embodiment adhesive is applied along a center line of therespective composite substrate before mounting to the web sausage.

In a still further embodiment adhesive is applied along the longitudinaloutside edge of the respective composite substrate adjacent respectiveleg cuff pieces before application to the web sausage.

In another embodiment of the invention, web structures for use as acombination leg cuff and containment flap are produced by supplying asubstantially endless substrate portion having a length dimension,securing extensible leg cuff pieces to the substrate portion atlongitudinally spaced locations, securing elastomeric elementslongitudinally along the length dimension of the substrate portion intransversely spaced relationship to the leg cuff pieces, and foldingopposing longitudinal outside edges of the substrate portion inwardlyand securing the outside edges to facing portions of the substrateportion to form a composite containment flap substrate.

Another method of making an absorbent article includes securingelastomeric elements to a continuous first web substrate, slitting thesubstrate longitudinally to form a pair of first substrate portions,securing the first substrate portions to a second substrate, with theelastomeric elements between the second substrate and the pair of firstsubstrate portions to form a base structure. An absorbent core andbodyside liner are applied to one side of the base structure and anouter cover is applied to the opposing side of the base structure toform a web sausage.

In one embodiment, the method includes the steps of folding outsideedges of the base structure inwardly into a substantially J-shapedconfiguration and ultrasonically bonding the edges.

Another embodiment includes the steps of driving the base structure in afirst nip at a first speed, then driving the base structure through asecond nip at a second slower speed, such that ruffles are formed in thebase structure between the first and second nips, the second nipsecuring the bodyside liner and absorbent care to the base structurewhile the base structure is in the ruffled condition.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a representative side elevation of apparatus for makingabsorbent articles of the invention.

FIG. 2 shows a top view of a continuous containment flap substrate thatsupports elastomeric elements and spaced leg cuff pieces.

FIG. 3 shows a cross-sectional view of the substrate, elastomericelements, and leg cuff pieces, and is taken at 3—3 of FIG. 2.

FIG. 4 shows a cross-sectional view of the substrate, elastomericelements, and leg cuff pieces, and is taken at 4—4 of FIG. 2.

FIG. 5 shows a cross-sectional view of the substrate portions beingfolded, after separation, with elastomeric elements and leg cuffsthereon, and is taken at 5—5 of FIG. 2.

FIGS. 6A and 68 show a cross-sectional view of the composite containmentflap substrates formed by folding of the substrate portions, and istaken at 6—6 of FIG. 2.

FIGS. 7A and 7B show a cross-sectional view of composite substrates ofFIGS. 6A and 68, with adhesive applied thereto.

FIG. 8 shows a cross-sectional view showing the composite substratesapplied to the web sausage.

FIG. 9 shows a representative top view of the composite substrates beingapplied to the web sausage.

FIG. 10 shows a cross-sectional view of a first embodiment of absorbentarticles formed by apparatus and methods of the invention.

FIG. 11 shows a cross-sectional view of a second embodiment of absorbentarticles formed by apparatus and methods of the invention.

FIG. 12 shows a representative pictorial view of a second embodiment ofapparatus used in the invention.

FIG. 13 shows a cross-sectional view of a base structure, and is takenat 13—13 of FIG. 12.

FIG. 14 shows a cross-sectional view of the J-folded base structure, andis taken at 14-14 of FIG. 12.

FIG. 15 shows a cross-sectional view of a web sausage formed by theapparatus and methods of the invention and taken at 15—15 of FIG. 12.

The invention is not limited in its application to the details of theconstruction and the arrangement of the components set forth in thefollowing description or illustrated in the drawings. The invention iscapable of other embodiments or of being practiced or carried out invarious ways. Also, it is to be understood that the terminology andphraseology employed herein is for purpose of description andillustration and should not be regarded as limiting. Like referencenumerals are used to indicate like components.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

The present invention is directed toward methods to produce absorbentarticles, particularly disposable absorbent articles. The articles canbe placed against or in proximity to the body of a wearer to absorb andcontain various exudates discharged from the body. An exemplary methodforms leg cuffs and containment flaps from a substrate comprising acontinuous web of material.

FIG. 1 shows an assembly system 8 for forming absorbent articles. System8 includes a compression nip device 10 that secures a bodyside liner 12and an absorbent core 13 (shown in FIGS. 10 and 11) to an outer cover14. Compression nip device 10 comprises first and second rolls 16, 18forming a first nip 20. First nip 20 applies pressure to the bodysideliner 12, outer cover 14, and absorbent core 13 therebetween, to form anabsorbent article web sausage 22. Absorbent article web sausage 22 thenmoves to die cutter 24. Die cutter 24 includes an anvil roll 26 and aknife roll 28. Die cutter 24 cuts leg cut-outs 30 from web sausage 22 asshown in FIG. 9. Web sausage 22 proceeds to ear applicator 32. Earapplicator 32 secures ears 34, shown in FIG. 9, to web sausage 22 formounting absorbent article 35 to a user. Ear applicator 32 includes avacuum transfer roll 36 which supports ears 34 and a knife roll 38.Knife roll 38 cuts ears 34 from ear material 40 fed from supply roll 42.An elliptical rotary anvil 44 with pucks 46 intermittently forms a nipwith transfer roll 36 to secure ears 34 on web sausage 22. Rotary anvil44 rotates in a counterclockwise direction shown by arrow 48 wherebypucks 46 are moving in the same direction as web sausage 22 when thepucks interact with the web sausage.

Meanwhile, a substrate 50 of continuous web material is drawn from asupply roll 52. One or more elastomeric elements 54 are drawn from oneor more elastomeric element supply rolls 56. The elastomeric elements 54pass through thread guides 58 of guide apparatus 60. Guide fingers 62guide elastomeric elements 54 toward substrate 50. Glue gun 64 appliesadhesive to elastomeric elements 54. Elastomeric elements 54 preferablyextend longitudinally along the length of the substrate at substantiallyequal distances from central axis 87 shown in FIGS. 2 and 3. Anvil rolls66, 68 ensure securement of elastomeric elements 54 to substrate 50 byapplying pressure to the elastomeric elements and the substrate.

Substrate 50 then moves to leg cuff piece applicator 70. Preferablysubstrate 50 travels a substantially straight line path from supply roll52 through anvil rolls 66, 68 to leg cuff piece applicator 70. Leg cuffpiece applicator 70 includes a glue gun 72 that applies glue to leg cuffmaterial 74. Pre-wrap roll 75 helps pre-feed/pre-wrap a variablevelocity vacuum transfer roll 76. Variable velocity vacuum transfer roll76 includes pucks 78 that support leg cuff pieces 80, and an anvil roll82 forms a second nip 84 with vacuum roll 76. A hot knife (not shown) onvacuum transfer roll 76 cuts extensible leg cuff pieces 80 to a sizepreferably greater than the length “L” of the opening at leg cut-outs 30shown in FIG. 9. Leg cuff piece applicator 70 then secures leg cuffpieces 80 to substrate 50 at transversely and longitudinally spacedlocations as shown in FIGS. 2 and 3. A full description of vacuumtransfer roll 76, as well as vacuum transfer roll 36, is set forth inpatent application Ser. No. 08/381,362 titled “Method and Apparatus forPlacing Discrete Parts onto a Moving Web” by Rajala et al, filed Jan.31, 1995 and hereby incorporated by reference in its entirety.

Cutting wheel 86 cuts or slits substrate 50 into two substrate portions50A, 50B as shown in FIG. 2, forming slit 85 along the length ofsubstrate 50. Glue guns 88, 90 then apply adhesive to substrate portions50A, 50B as shown in FIG. 4.

Folding mechanism 92, represented by an angle having arms aligned withthe direction of movement of substrate 50 in FIG. 1, then folds bothinside and outside portions of substrates 50A, 50B forming compositecontainment flap substrates 51A, 51B. Each composite containment flapsubstrate comprises an integral combination of a containment flap 98 andleg cuff 100 as shown in FIGS. 6A and 68.

Next, anvil rolls 102, 104 apply pressure at nip 106 ensuring that thecombination containment flaps 98/leg cuffs 100 of composite substrates51A, 51B are properly bonded by the adhesive and shaped to the desiredfolded configuration. Glue guns 108, 110 apply adhesive to respectivecomposite substrates 51A, 51B near turning roll 112. Turning roll 112turns respective composite substrates 51A, 5B toward web sausage 22 forsecurement thereto. Ultrasonic bonder 114 then bonds the compositesubstrates 51A, 51B comprising leg cuffs 100 and containment flaps 98 toweb sausage 22, and finishes the edges of the respective compositesubstrates. Ultrasonic bonder 114 includes first and second bandingunits, each unit including an ultrasonic rotary anvil roll 116 and arotary ultrasonic horn 118 forming a respective nip 119.

Bodyside liner 12 may be manufactured from a wide selection of webmaterials, such as porous foams, reticulated foams, apertured plasticfilms or natural fibers. For example, bodyside liner 12 may comprisewood or cotton fibers. Other possible materials are synthetic fibers,such as polyester or polypropylene fibers, or a combination of naturaland synthetic fibers. Bodyside liner 12 is suitably utilized to helpisolate, from the wearer's skin, the liquids held in absorbent core 13.

Various woven and nonwoven fabrics can be used for bodyside liner 12.For example, bodyside liner 12 may be composed of a meltblown orspunbonded web of polyolefin fibers. Bodyside liner 12 may also comprisea carded and/or bonded web composed of natural and/or synthetic fibers.Bodyside liner 12 may also be composed of a substantially hydrophobicmaterial wherein the hydrophobic material is treated with a surfactantor otherwise processed to impart a desired level of wettability andhydrophilicity.

In a particular embodiment of the present invention, bodyside liner 12may comprise a spunbonded polypropylene fabric composed of about 2.8-3.2denier fibers formed into a web having a basis weight of about 22 gramsper square meter and a density of about 0.06 grams per cubic centimeter.A preferred fabric is treated with about 0.3 weight percent of asurfactant.

Bodyside liner 12 can be formed from a single layer, or may comprise amultiplicity of components, layers, or partial layers, which correspondto any of the materials disclosed herein, as well as others known in theart.

Absorbent core 13 suitably comprises a matrix of hydrophilic fibers,such as a web of cellulosic fluff, preferably in combination with ahigh-absorbency material commonly known as superabsorbent material. In aparticular embodiment, absorbent core 13 comprises a mixture ofsuperabsorbent hydrogel-forming particles and wood pulp fluff. In placeof the wood pulp fluff, one may use synthetic, polymeric, meltblownfibers or a combination of meltblown fibers and natural fibers. Thesuperabsorbent material may be substantially homogeneously mixed withthe hydrophilic fibers or may be otherwise combined into the absorbentcore.

Alternatively, absorbent core 13 may comprise a laminate of fibrous websand superabsorbent material or other suitable means of maintaining asuperabsorbent material in a localized area.

Absorbent core 13 can have any of a number of shapes. For example, theabsorbent core may be rectangular, T-shaped or I-shaped. It is generallypreferred that absorbent core 13 be narrower in the crotch portion thanin the rear and/or front portions. Absorbent core 13 generally does notextend over the entire dimensions of cuter cover 14 or bodyside liner12.

The superabsorbent material in absorbent core 13 can be selected fromamong natural, synthetic and modified natural polymers and materials.The high absorbency materials can be inorganic materials, such as silicagels, or organic compounds, such as crosslinked polymers. The termcrosslinked refers to any means for effectively rendering normallywater-soluble materials substantially water insoluble but swellable,whereby absorbent properties are available but the swelled material issubstantially immobile after absorbing water-based liquids. Such meanscan include, for example, physical entanglement, crystalline domains,covalent bonds, ionic complexes and associations, hydrophilicassociations such as hydrogen bonding, and hydrophobic associations orVan der Waals forces.

Outer cover 14 can be formed from a single layer, or from multiplecomponents, layers, or partial layers, of material, such that theresulting outer cover is substantially impermeable to liquids. A typicalouter cover 14 may be manufactured from a thin plastic film or otherflexible liquid-impermeable material. For example, outer cover 14 can beformed from a polyethylene film having a thickness of from about 0.012millimeters to about 0.051 millimeters. When it is desirable that theouter cover 14 have a more clothlike feeling, it may comprise apolyethylene film laminated to a surface of a nonwoven web, such as aspunbonded web of polyolefin fibers. For example, a polyethylene filmhaving a thickness of about 0.015 millimeters may have thermally orotherwise laminated thereto a spunbonded web of polyolefin fibers havinga thickness from 1.5 to 2.5 denier per filament, which nonwoven web hasa basis weight of about 24 grams per square meter. Further, outer cover14 can be formed of a woven or nonwoven fibrous web which has beentotally or partially constructed or treated to impart a desired level ofliquid impermeability to selected regions that are adjacent or proximatethe absorbent core 13. Still further, outer cover 14 may optionally becomposed of a micro-porous material which permits vapors to escape fromabsorbent core 13 and through outer cover 14 while preventing liquidexudates from passing through the outer cover.

Ears 34 preferably comprise mechanical fasteners such as hooks of a hookand loop fastening system, and are preferably mounted on outer cover 14.Cooperative attachment loop material or other fastener surface isprovided at e.g. the outer surface (not shown) of outer cover 14 on e.g.the front portion of the respective absorbent articles 35. The exemplaryloop material is adapted to releasably engage with hook material on therespective ear. Other well known fastening systems can also be used tosupport absorbent article 35 on a user. For example, a cohesive system,an adhesive fastener system or the like may also be utilized to securethe absorbent article about the crotch and lower trunk portion of theuser.

Operation of the absorbent article assembly system 8 is as follows.First and second anvil rolls 16, 18 of compression nip device 10 formfirst nip 20. At least one of the rolls is driven by a drive (notshown). Rolls 16, 18 press continuous webs of bodyside liner 12 andouter cover 14 against each other at nip 20, trapping spaced elements ofabsorbent core 13 therebetween, thereby securing bodyside liner 12,absorbent core 13 and outer cover 14 to one another at nip 20,preferably by gluing. These three elements, when secured to each other,mutually form absorbent article web sausage 22, with spaced elements ofabsorbent core 13 being disposed between bodyside liner 12 and outercover 14. Other known devices can also be utilized to form web sausage22.

Bodyside liner 12 and outer cover 14 preferably have substantially thesame dimensions. The webs of bodyside liner 12 and outer cover 14 arepreferably aligned so their outer edges are substantially aligned withand contact one another when web sausage 22 is formed. The so joinedwebs of bodyside liner 12, outer cover 14, and the spaced elements ofabsorbent core 13 comprise precursors of respective serially alignedabsorbent articles 35 along the length of web sausage 22. As indicatedin the drawings, web sausage 22 comprises a continuous web sausage.

After leaving nip 20, web sausage 22 then enters die cutter 24 whichcuts leg cut-outs 30. The cutting is done by knife roll 28 incombination with anvil roll 26. Knife roll 28 has knives (not shown)arranged in a pattern consistent with making leg cut-outs 30 illustratedin FIG. 9. Preferably both leg cut-outs 30 on a given absorbent articleprecursor are made simultaneously by spaced knives (not shown).Absorbent core 13, preferably is not contacted by any of the knives ofdie cutter 24. Preferably, none of the layers forming web sausage 22contain elastomeric material.

As used herein, “elastomeric material” means material which can bestretched about 50% to about 450% in one direction, and which willreturn to approximately its original dimensions when released.Preferably all of the material removed by die cutter 24 comprisesnon-elastomeric material.

Ear applicator 32 cuts, and thereby creates, ears 34 from an incomingweb of ear material 40 drawn from supply roll 42, and transfers the earsto web sausage 22. Knife roll 38 rotates with vacuum transfer roll 36,cutting ear material 40 to create the ears. Elliptical rotary anvil 44rotates about central axis 47 as shown by arrow 48 in FIG. 1. Rubberpucks 46 on rotary anvil 44 intermittently form a nip with transfer roll36 and thereby assist in securing ears 34 to web sausage 22. After anear 34 is secured, the respective rubber puck 46 rotates out of contactwith web sausage 22. The opposing puck 46 then rotates into suchcontact, to mount another ear 34 when rotary anvil 44 has rotated about180 degrees. Such process is repeated by continuing rotation of rotaryanvil 44 and transfer roll 36. The ears can be secured to web sausage 22by adhesive or other methods. Pucks (not shown) on vacuum transfer roll36 rotate into contact with web sausage 22 for transferring ears 34 tothe web sausage.

While compression nip device 10, die cutter 24, and ear applicator 32are operating, substrate 50 comprising a continuous web material isbeing drawn from supply roll 52. Elastomeric element supply roll 56supplies continuous threads of elastomeric elements 54 to guideapparatus 60. Guide apparatus 60 utilizes thread guides 58 and guidefingers 62 to place and secure elastomeric elements 54 to substrate 50.

Substrate 50 can comprise any of the materials mentioned as suitable forbodyside liner 12. Substrate 50 preferably comprises a soft nonwovenfabric material. Substrate 50 has a length dimension. Substrate 50comprises a main body extending along the length dimension, and opposingouter edges 53.

Glue gun 64 applies adhesive to elastomeric elements 54 just before theelastomeric elements are secured to substrate 50. Elastomeric elements54 are adhered at opposing inner locations spaced both from central axis87 of substrate 50 as shown in FIG. 2 and from the opposing outer edges53 of substrate 50. Central axis 87 runs the length of substrate 50 andis substantially centered in the substrate. Elastomeric elements 54preferably continuously run the entire length of substrate 50 andpreferably are spaced outwardly substantially equal distances fromcentral axis 87, and inwardly substantially equal distances from therespective outer edges 53. Preferably, spaced leg cuff pieces 80, whichwill be described in more detail later, are spaced outwardly fromelastomeric elements 54 as shown in FIG. 2. Substrate 50 then passesthrough anvil rolls 66, 68 which apply pressure to elastomeric elements54 and substrate 50, ensuring securement of the elastomeric elements tothe substrate.

Any number of elastomeric elements 54 can be utilized in the invention.FIGS. 3-5 show a total of four elastomeric elements 54 applied tosubstrate 50. However, any number of elastomeric elements, preferably aneven number, can be secured to the substrate. Elastomeric elements 54can comprise strands, ribbons, or one or more layers of a polymericand/or elastomeric material, such as a rubber material, which is adheredto substrate 50 in a stretched condition. A suitable elastomeric elementcan be composed of a 470 decitex LYCRA elastomer, a 620 decitex LYCRAelastomer or other elastomers with suitable characteristics. Elastomericelements 54 create elastic tension for containment flaps 98 andtherefore must be of appropriate strength and size.

While continuous elastomeric elements 54 intermittently glued tosubstrate 50 are the preferred embodiment, the elastomeric elements canbe discontinuous, having a length substantially the same as leg cuffpieces 80 shown in FIG. 2. In such an embodiment, elastomeric elements54 can be attached to substrate 50 in a manner similar to leg cuffpieces 80. FIG. 3 shows one embodiment of the invention incross-section, including two spaced pairs of elastomeric elements 54about which containment flaps 98 are folded.

Glue gun 64 can comprise a single glue gun with multiple ports, or aplurality of individual glue guns for each elastomeric element 54 beingsecured to substrate 50. Glue guns 64 preferably operate in a timed orregistered manner to intermittently glue elastomeric elements 54 tosubstrate 50. While FIG. 1 shows glue gun 64 applying adhesive toelastomeric elements 54, adhesive can instead be applied directly tosubstrate 50 at locations where guide apparatus 60 places elastomericelements on the substrate, or can be applied to both substrate 50 andelements 54. The glued portions of elastomeric elements 54 preferablyextend approximately the same length as leg cuff pieces 80 andpreferably along the same length of substrate 50 as the leg cuff piecesin registration with leg cuff pieces 80; but elastomeric elements 54preferably are spaced inwardly from leg cuff pieces 80 when both areapplied to substrate 50.

While gluing is the preferred method of attaching elastomeric elements54 to substrate 50, other known methods, such as melt bonding or heatbonding can also be utilized.

Substrate 50 moves from guide apparatus 60 through the nip formed byrolls 66, 68, then to leg cuff piece applicator 70. The dashed line inFIG. 1 indicates that the elastomeric guide apparatus 60 can be in linewith leg cuff piece applicator 70, and is placed underneath apparatus 60merely for purposes of illustration.

Leg cuff piece applicator 70 applies pairs of opposed spaced leg cuffpieces 80 to substrate 50 using variable velocity vacuum transfer roll76 having pucks 78 that support leg cuffs 80, representativelyillustrated in FIG. 1. Glue gun 72 supplies adhesive to a continuous webof leg cuff material 74.

In an alternative embodiment (not shown), glue gun 72 is positionedadjacent substrate 50. Glue gun 72 is timed or registered tointermittently apply adhesive to opposed spaced portions of substrate 50and along a length of substrate 50 therebetween. Leg cuff pieces 80 arebrought adjacent substrate 50 of the leg cuff pieces with the ends 81and one side of each leg cuff 80 in registration with the adhesive onsubstrate 50, and are secured to the substrate.

Pre-wrap roll 75 helps pre-feed/pre-wrap vacuum transfer roll 76 andmaintain leg cuff material 74 in continuous contact with vacuum transferroll 76 before, during and after cutting of the leg cuff material. Thevariable rotational velocity of vacuum transfer roll 76 is controlled tooperate at a first rotational velocity whereby the speed of a segment ofthe roll substantially equals the speed of leg cuff material 74 whenreceiving a length of the leg cuff material onto the segment of theroll. The continuous web of leg cuff material 74 is then cut intoindividual leg cuff pieces 80 by a hot knife (not shown) on vacuumtransfer roll 76, and is supported by vacuum on vacuum transfer roll 76.

When leg cuffs are to be applied to substrate 50, the rotationalvelocity of the respective segment is changed such that the speed of thesegment substantially equals the speed of substrate 50. By matching thesurface speed of the segment to the speed of substrate 50, propertransfer is effected. Variable velocity vacuum roll 76 applies leg cuffpieces 80, such as by adhesive pressure, to substrate 50 with assistanceof roll 82.

Individual extensible leg cuff pieces 80, at least when extended, have alength longer than the length of leg cut-outs 30. Prior to securement tosubstrate 50, leg cuff pieces 80 preferably are extended to a dimensionrepresenting about 5% to about 95% of their stretch-to-stop elongation,and most preferably 20% to 50% of their stretch-to-stop elongation. Legcuff pieces 80 are secured to substrate 50 in such partially stretchedcondition, with substrate 50 extended preferably to its stretch-to-stoplimit. At minimum, the percent elongation of leg cuff piece 80 atsecurement to substrate 50 is greater than the percent elongation ofsubstrate 50. Accordingly, leg cuff pieces 80 provide a degree ofretraction properties different from, preferably greater than, theretraction properties of substrate 50. FIG. 3, taken at 3—3 in FIG. 2,shows the preferred spacing of leg cuff pieces 80 on substrate 50 onopposing sides of elastomeric elements 54. Leg cuff pieces 80 are atspaced opposing locations with respect to each other along substantiallythe same length of web substrate 50.

Web material 74 used to make leg cuff pieces 80 can comprise, forexample, a laminate including first and second outer nonwoven facinglayers on opposing sides of an elastomeric core layer, the elastomericcore layer comprising a thermoplastic elastomeric composition such as astyrene ethylene butylene styrene terpolymer. Extensible leg cuff pieces80 can also comprise a plurality of elastomeric elements comprisingstrands, ribbons or the like secured in a stretched condition to anonelastomeric piece of material, the elastomeric elements extendingalong the length of the nonelastomeric piece of material. Leg cuffpieces 80, as shown, are discontinuous structures comprising elastomericmaterial.

Examples of other materials of which all or portions of leg cuff pieces80 may be comprised include, without limitation, spandex/nonwovenlaminated webs, extruded elastomeric webs or meltblown webs,cross-machine direction stretchable web materials made with stretchablenonwovens, stretchable foam webs and the like.

From leg cuff piece applicator 70, substrate 50 moves to cutting wheel86. Cutting wheel 86 includes a knife or blade (not shown) which slitssubstrate 50 along its length into two substrate portions 50A, 50B asshown at dashed central axis 87 in FIG. 3. A slit 85, formed by cuttingwheel 86, is shown in FIG. 9. While cutting wheel 86 is disclosed, theinvention contemplates other well known elements performing the samecutting function. For example, a tension bar having a stationary ormoving blade mounted at a proper angle with respect to substrate 50 canslit the substrate along its length.

Folding mechanism 92 is represented by an angle or bend in substrateportions 50A, 50B of substrate 50 in FIG. 1. Folding mechanism 92 foldssubstrate portions 50A, 50B to form composite substrates 51A, 51B.Folding mechanism 92 comprises a well known apparatus that folds webs orsubstrates. Such a folding apparatus is shown in U.S. Pat. No.4,900,384, issued Feb. 13, 1990 to Sanders et al and herein incorporatedby reference. Other similar folding mechanisms are well known in the artand can be utilized with assembly system 8.

Glue guns 88, 90 apply adhesive to substrate portions 50A and 50Brespectively, as shown in FIG. 4. Folding mechanism 92 then foldssubstrate portions 50A, 50B along the continuous length thereof as shownin FIG. 5 securing the outside edges to facing portions of the mainbody. When folding is completed, composite substrates 51A, 51B areformed. Each integrated continuously folded composite substrate 51A, 51Bcomprises a leg cuff 100 integral with a containment flap 98 as shown inFIGS. 6A, 6B. Driven anvil rolls 102, 104, forming nip 106, thencompress composite substrates 51A, 51B to ensure securement of theadhesive, to thereby secure the folds.

Turning roll 112 then turns composite substrates 51A, 51B towardultrasonic bonder 114. Glue guns 108, 110 apply adhesive 111 tocomposite substrates 51A, 51B, preferably as lines of adhesive at acentral location along the length of each composite substrate, as shownin FIGS. 7A and 7B. The integral leg cuffs 100 and containment flaps 98of integral folded composite substrates 51A, 51B are then moved intoposition below web sausage 22 as shown in the cross-sectional view ofFIG. 8 and secured thereto. Of course, composite substrates 51A, 51Bcan, in the alternative, be placed above web sausage 22 or in any otherspaced arrangement. Web sausage 22 is a representation of, for example,bodyside liner 12, absorbent core 13, outer cover 14 and any otherelement contained between bodyside liner 12 and outer cover 14.

Ultrasonic bonder 114 then finishes and smoothes the absorbent article.Ultrasonic bonder 114 includes anvil rolls 116 and rotary ultrasonichorns 118. Each rotary ultrasonic horn 118 is biased against arespective anvil roll 116. As web sausage 22 and composite substrates51A, 51B pass, each rotary ultrasonic horn 118 vibrates, generatingultrasonic energy, preferably at a frequency of about 20 KHz. Theultrasonic energy finishes and smoothes raw edges of each of the legcuffs 100 and smoothes unevenness due to their elasticity andunregistered gluing. Each ultrasonic horn 118 is disposed over adifferent one of the lines of spaced leg cuffs 100 being secured to websausage 22. A respective ultrasonic horn 118 typically has a pattern 117of dots forming a quilted or other pattern or look. This quilted pattern117 is formed by blending portions of composite substrates 51A, 51B intoweb sausage 22 with ultrasonic energy as shown in FIG. 9. This patternprevents curl of leg cuffs 100 and/or containment flaps 98, caused bytheir elasticity and unregistered gluing, from altering the appearance,or the consistency of performance, of absorbent article 35. Thus, afterthe ultrasonic treatment, absorbent articles 35 have a smooth, finishedlook where composite substrates 51A, 51B are secured to web sausage 22.

While an ultrasonic bonder 114 is disclosed, other well known devicescan be utilized to join composite substrates 51A, 51B to web sausage 22.For instance, ultrasonic bonder 114 can be replaced by a pair of anvilrolls forming a nip. The anvil rolls compress web sausage 22 againstcomposite substrates 51A, 51B ensuring adhesive 111 secures the elementsto each other.

Downstream of ultrasonic bonder 114, web sausage 22 is cut into aplurality of absorbent articles or workpieces. A cutting machine (notshown) severs web sausage 22 transversely across its width. The cuttingmachine is timed or registered to sever web sausage 22 at locationsspaced along the length of the web sausage, and substantially centeredbetween longitudinally spaced leg cuffs 80. The cutting machine alsosevers elastomeric elements 54, if they have not already been severedearlier in the process.

Severing of web sausage 22 is done by any of a variety of well knowncutting machines. For example, a final cut-off roll (not shown) having aknife (not shown) extending across the roll, in combination with ananvil roll (not shown) severs web sausage 22. There is preferably a gapabout 0.25 inch wide between the cut-off roll and the anvil roll (notshown). The absorbent articles severed from web sausage 22 aretransferred by conveyor to a stacker (not shown).

In the embodiment shown in FIGS. 7A and 7B, adhesive 111 is placed as acontinuous line of adhesive between containment flap 98 and leg cuff100. This embodiment forms a “V-cuff” type absorbent article 35 as shownin FIG. 10. Absorbent article 35 includes absorbent core 13, bodysideliner 12 and outer cover 14. Leg cuffs 100 extend outwardly fromabsorbent core 13, along bodyside liner 12 and outer cover 14, andcontainment flaps 98 extend upwardly at an angle from the generalstructure formed by absorbent core 13, bodyside liner 12 and outer cover14.

FIG. 11 shows another embodiment where adhesive is applied as acontinuous line of adhesive along the outside edge of leg cuff 100, ascompared to FIG. 8. Leg cuff 100 glues to web sausage 22 and extendsoutwardly therefrom. Containment flap 98 is folded inwardly to contact auser's body and contain exudates. Folding can be accomplished by afolding device, as described earlier, or any other conventional foldingapparatus. An ultrasonic bonder (not shown) can ensure the fold remainsin place by bonding the outward folded edge of the flap. The embodimentof FIG. 11 generally comprises a “C-cuff” type absorbent article 35having leg cuffs formed in a C-shaped structure as illustrated in FIG.11.

While FIG. 1 shows glue guns 108, 110 applying adhesive to compositesubstrates 51A, 51B, the glue can be applied directly to web sausage 22at locations that will contact selected parts of composite substrates51A, 51B. Once again, the adhesive preferably comprises a continuousline of glue along the length of web sausage 22.

While FIG. 1 shows ear applicator 32 applying ears 34 to web sausage 22before applying substrate portions 50A, 50B to the web sausage, theorder can be reversed and ear applicator 32 can follow ultrasonic bonder114. Further, the order of other work stations, such as guide apparatus60 which applies elastomeric elements 54, and leg cuff piece applicator70, can be changed.

BASE STRUCTURE EMBODIMENT

FIG. 12 shows another embodiment of absorbent article assembly system 8that forms containment flaps 98 and leg cuffs 100 on a single workpiece.The workpiece supports bodyside liner 12 and outer cover 14. Ear piecebonding device 120 comprises ultrasonic horns 122 and anvil rolls 124that intermittently bond ears 34 to outer cover 14. Leg cut-out devices126 sever leg cut-outs 30 from outer cover 14 which moves in a directionshown by arrow 128.

Elsewhere, first substrate 50 is fed from supply roll 52. A cuttingdevice 129 including a cutting wheel 130 and a bottom roll 131 having ashoulder, slit substrate 50 into two substrate portions 50A, 50B. AZ-bar 132 spreads or spaces substrate portions apart from one another.Elastomeric supply rolls 56 supply elastomeric elements 54 throughthread guides 58 to substrate portions 50A, 50B. Intermittent glue gun133 applies adhesive to elastomeric elements 54 to secure the elementsto respective substrate portions 50A, 50B.

In the meantime, a second base roll 134 unrolls a second substrate 136,preferably comprising a polyethylene material. Turning roll 148 turnssecond substrate 136 downwardly toward first substrate 50. Then secondsubstrate 136 and first substrate 50 are joined by a pair of rails 150,152 forming a nip. First substrate 50 and second substrate 136 togetherform a base structure 154 having elastomeric elements 54 therebetween.Base structure 154 proceeds to J-fold device 156 including anvil rolls158, 160. J-fold device 156 includes folding board 161 that folds theoutside edges of base structure 154 inwardly and upwardly to form endsof containment flaps 98. J-fold bonder 162, comprising anvil rolls 164and ultrasonic horns 166, then bonds or strengthens the J-folded edgesof base structure 154. Base structure 154 then moves to elastomericelement cutter 168. Elastomeric element cutter 168 comprises a cutterroll 170 and an anvil roll 172. When cutter element 174 of cutter roll170 contacts base structure 154 in a nip formed between rolls 170, 172,elastomeric elements 54 are crushed, and thereby severed. Turning roll176 turns the direction of travel of base structure 154.

Elsewhere, bodyside liner supply roll 178 supplies a continuous web ofbodyside liner material 12. Surge layer supply roll 180 supplies surgelayer material 182. Surge layer 182 enters surge layer applicator 184where the surge layer is cut and applied at spaced locations along theweb of bodyside liner material 12. Surge layer applicator 184 includes afirst conveyor 186 that receives surge layer material 182. A glue gun188 applies adhesive to surge layer 182 while the layer is traversingfirst conveyor 186. A knife roll 190 and a rotary anvil 192 form a nip.When a transverse cutting blade (not shown) on knife roll 190 contactssurge layer 182, the surge layer is severed. Then a second fasterseparating conveyor 194 receives the severed segment 193 of surge layer182 and advances the segment to bodyside liner 12. Surge layer segment193 is secured to bodyside liner 12 by the adhesive from glue gun 188.Bodyside liner 12, with surge layer segment 193 secured thereto, thenfollows a pair of turning rolls 196, 198 to absorbent core applicator200.

Arrow 201 shows the direction absorbent core material (not shown)travels to reach absorbent core applicator 200. Absorbent coreapplicator 200 places absorbent core 13 over bodyside liner 12 and surgelayer 182.

Absorbent core applicator 200 includes a first conveyor 202 operating ata first speed and a second conveyor 204 operating at a second fasterspeed. Absorbent core applicator 200 includes a pad cut-off device 206comprising an anvil roll 208 and a knife roll 209. Pad cut-off device206 severs an absorbent core 13 from a length of absorbent care material203 and absorbent core 13 is transferred to folding device 210.

Folding device 210 folds a portion of bodyside liner 12 around absorbentcore 13. Glue gun 212 applies adhesive to bodyside liner 12.

Base structure 154 traverses a first fast nip 214 formed by anvil rolls216, 218. Then base structure 154 advances to a second nip 220, formedby rolls 222, 224, which rolls 222, 224 are rotating slower than firstnip 214. Second nip 220 joins base structure 154 to bodyside liner 12supporting absorbent core 13. Folding device 226 then folds containmentflaps 98, formed in base structure 154, inwardly and downwardly aroundabsorbent core 13. Ultrasonic bonder 228 comprising anvil rolls 230 andultrasonic horns 232 then bonds or secures containment flaps 98 of basestructure 154 in an inwardly folded downward direction. Folding device226, as well as folding device 210 mentioned earlier, can comprise thefolding apparatus of U.S. Pat. No. 4,900,384, or other foldingmechanisms well known in the art.

Base structure 154 turns on turning roil 234 to join outer cover 14having leg cut-outs 30 and ears 34 at compression nip device 236. Gluegun 140 applies adhesive to outer cover 14. Compression nip device 236including anvil rolls 238, 240 secures outer cover 14 to the combinationof bodyside liner 12 and base structure 154 forming web sausage 22. Websausage 22 then moves to other work stations along a path shown by arrow242.

In operation, ear piece bonding device 120 secures ears 34 to outercover 14. Ears on outer cover 14 enter along a path shown by arrow 128.Separate ultrasonic horns 122, in combination with rotary anvil rolls124, bond opposing ears spaced outwardly on outer cover 14. Ultrasonichorns 122, preferably operate at 20 KHz.

While an ultrasonic bonding device is disclosed, other known securingmethods, such as adhesive bonding of ears 34 to outer cover 14 can beutilized. Furthermore, ears 34 can be attached to outer cover 14 or websausage 22 later in the process.

Leg cut-out devices 126 then create leg cut-outs 30 in outer cover 14.The cutting loci of the respective leg cut-out devices effectively moveinwardly and outwardly while outer cover 14 passes underneath to formthe shape of leg cut-outs 30. A variety of known cutter devices areacceptable for leg cut-out devices 126.

Elsewhere in absorbent article assembly system 8, first substrate 50 isfed from supply roll 52. Substrate 50 preferably comprises a spunbond,non-woven material. However, substrate 50 can comprise any of thematerials described earlier for bodyside liner 12.

Cutting device 129 slits substrate 50 along its length into twosubstrate portions 50A, 50B having substantially the same width. Cuttingdevice 129 includes a rotating blade wheel 130 centered on substrate 50.Substrate portions 50A, 50B are spread apart by Z-bar 132 into a pair ofspaced webs having approximately the same width. Z-bar comprises a pairof outwardly angled arms that space apart substrate portions 50A, 50B.The spacing of substrate portions 50A, 50B reduces the amount ofmaterial used in the manufacturing process, and thereby decreases thecost of the absorbent articles 35 being manufactured. Preferred spacingbetween substrate portions 50A, 50B is about 3 to 4 inches.

As substrate portions 50A, 50B advance, elastomeric elements 54 fromelastomeric supply rolls 56 travel through thread guides 58 to substrateportions 50A, 50B. Glue gun 133 intermittently applies adhesive toelastomeric elements 54 and/or substrate portions 50A, 50B depending onthe elements' relative positions.

Meanwhile, second substrate 136 advances from a second base roll 134toward direction changing roll 148 as shown in FIG. 12. When secondsubstrate 136 meets first substrate portions 50A, 50B, at rotary anvilrolls 150, 152, the substrate and substrate portions are secured to oneanother. Adhesive from glue gun 133 and pressure between the rolls 150,152 secure elastomeric elements 54 between first substrate portions 50A,50B and second substrate 136, and secures first substrate portions 50A,50B to second substrate 136 to form base structure 154 as shown in FIG.13. Base structure 154 has a main body extending along a lengthdimension, opposing outside edge portions, and opposing outside edges155 on the outside edge portions.

While second substrate 136 preferably comprises polyethylene material,it can also comprise the materials set forth earlier for outer cover 14or bodyside liner 12. Substrate 136 preferably is impermeable toliquids.

Base structure 154 then advances to J-fold device 156. Folding board 161folds the ends of base structure 154 into substantially a J-shape asshown in FIG. 14. The J-folded base structure 154 advances to rotaryanvil rolls 158, 160 forming a nip. The nip squeezes and compresses basestructure 154 so the ends maintain their shapes.

Base structure 154 advances to J-fold ultrasonic bonder 162. J-foldultrasonic bonder 162 includes ultrasonics horns 166 that vibrate atultrasonic frequencies known to those skilled in the art. Rotary anvilrolls 164, combined with horns 166, form a nip. Ultrasonic energyapplied to base structure 154 in the nip bonds the J-fold shape at theoutside edges or creases of the base structure. The pair of ultrasonichorns 166 and anvil rolls 164 are spaced apart as shown in FIG. 12.Ultrasonic bonder 162 ensures the J-folded edges of base structure 154maintain their shape shown in FIG. 14.

As base structure 154 advances, elastomeric element cutter 168 crushesor sufficiently weakens the elastomeric elements 54 inside the basestructure so the elements snap or break without cutting or damagingeither of substrates 50, 136. Elastomeric element cutter 168 includes acutter roll 170 with a cutter element 174 and an anvil roll 172. Cutterelement 174 passes transversely across base structure 154 upon rotationof cutter roll 170. When cutter element 174 contacts base structure 154,it applies a pressure great enough to crush elastomeric elements withinthe base structure. Cutter element 174 does not have an edge sharpenough to damage substrates 50, 136. The severing of elastomericelements 54 occurs at approximately the top and back side edges ofyet-to-be-formed absorbent articles 35. Turning roll 176 then turns basestructure 154 toward a workstation that mounts absorbent core 13 andbodyside liner 12 to the base structure. FIG. 14, taken between turningroll 176 and fast nip 214, shows base structure 154 reversed or invertedfrom the position shown in FIG. 13 due to turning roll 176.

At another location in assembly system 8, bodyside liner supply roll 178feeds bodyside liner 12 to surge layer applicator 184. Surge layersupply roll 180 supplies surge layer 182 to surge layer applicator 184.A first conveyor 186 operating at a first speed receives surge layer182. Glue gun 188, depending on its position, applies adhesive to afirst surface of surge layer 182 either before or after the layer is onthe conveyor. First conveyor 186 feeds surge layer 182 to a cuttingmechanism formed by knife roll 190 and rotary anvil roll 192. Knife roll190 includes a knife (not shown) that severs surge layer 182 transverseto its direction of travel to create discrete surge layer segments 193.A detached surge layer segment 193 then passes to second conveyor 194which operates at a greater speed than first conveyor 192. Secondconveyor 194 spaces apart surge layer segments 193 for spaced attachmentto bodyside liner 12 and for ultimate positioning adjacent absorbentcore 13.

When the absorbent article 35 is in use on a consumer, the surge layersegment 193 spreads exudates across its entire surface to enhance theabsorption of absorbent core 13. Surge layer segments 193 can be made ofwell known materials. Further, surge layer segments, and surge layer 182can comprise materials set forth in U.S. patent application Ser. No.206,986 by C. Elis and D. Bishop, entitled, “Fibrous Nonwoven Web SurgeLayer for Personal Care Absorbent Articles and the Like”, filed Mar. 4,1994; and U.S. patent application Ser. No. 206,069 by C. Elis and R.Everett, entitled, “Improved Surge Management Fibrous Nonwoven Web forPersonal Care Absorbent Articles and the Like”, filed Mar. 4, 1994; thedisclosures of which are herein incorporated by reference.

Bodyside liner 12, with a surge layer segment 193 thereon, then advancesaround turning rolls 196, 198 to absorbent core applicator 200. Arrow201 indicates the direction of travel of absorbent core material 203entering absorbent core applicator 200. Absorbent core applicator 200includes a first conveyor 202 that advances absorbent core material 203to pad cut-off device 206. Pad cutoff device 206 includes rotary kniferoll 209 and rotary anvil roll 208. Knife roll 209 has a blade 207extending across the roll transverse to the path of travel of absorbentcore material 203. Knife roll 209 severs the absorbent core materialacross its length to form absorbent cores 13. A respective absorbentcore 13 advances to second conveyor 204. Second conveyor 204 operates ata greater speed than first conveyor 202 and spaces apart consecutiveabsorbent cores 13 exiting pad cut-off device 206. While knife roll 209has been disclosed as the preferred cutting device, other well knownconventional absorbent core material cutting devices are well within thescope of the invention.

After conveyor 204 places absorbent core 13 adjacent bodyside liner 12,folding device 210 folds outside edges of continuous bodyside liner 12over the absorbent core. After folding, bodyside liner 12 preferablyextends over the top of absorbent core 13 by a distance of approximatelyone inch.

Glue gun 212 then applies adhesive to bodyside liner 12 as the elementsadvance. Base structure 154 enters nip 214 between rotary anvil rolls216, 218. Rolls 216, 218 of nip 214 rotate at a first surface speed thatis faster than the surface speed of rotation of rolls 222, 224 at secondnip 220 spaced downstream therefrom. The speed differential betweenfirst nip 214 and second nip 220 causes base structure 154 to ruffle orbunch up. First anvil rolls 216, 218 preferably operate at about 1.25times the speed of second rotary anvil rolls 222, 224 of second nip 220.Second-nip 220 secures ruffled base structure 154 to bodyside liner 12with absorbent core 13 therebetween. Absorbent core 13 generally doesnot cover the entire surface area of base structure 154 or bodysideliner 12. Base structure 154 comprising substrate portions 50A, 50B andsecond substrate 136 extends beyond bodyside liner 12 and even outercover 14.

While having the speed of rolls at first nip 214 faster than the speedat second nip 220 is preferred, the speeds can also be substantially thesame. In that instance, nip 214 and anvil rolls 216, 218 are notrequired. Furthermore, elastomeric element cutter 168 is not requiredbecause elastomeric elements 54 can be severed when web sausage 22 formsindividual absorbent articles 35.

While glue gun 212 is shown applying adhesive to bodyside liner 12, theglue gun can be repositioned for applying adhesive to base structure154.

From second nip 220, the combination bodyside liner 12 and basestructure 154 advance to folding device 226. Folding device 226 inwardlyfolds outside edges 155 of base structure 154 to form containment flaps98 as shown in FIGS. 14 and 15. Ultrasonic bonder 228 bonds basestructure 154 to itself to retain containment flaps 98 in the desiredorientation shown in FIG. 15. Ultrasonic bonder 228 includes rotaryanvil rolls 230 and ultrasonic horns 232. Ultrasonic horns 232, as shownin FIG. 12 send ultrasonic energy to the two facing portions of basestructure 154 to retain fold 157 of respective containment flaps 98.Desirably, ultrasonic horns 232 operate at 20 KHz.

FIG. 15 is not drawn to scale. The size or width of many elements hasbeen enlarged for purposes of illustration.

The combination of base structure 154/bodyside liner 12 turns on turningroll 234 and meets outer cover 14 including ears 34 at compression nipdevice 236. Compression nip device 236 includes anvil rolls 238, 240that compress outer cover 14 to base structure 154. Glue gun 140 appliesadhesive to outer cover 14. Further, glue gun 140 can be positioned toprovide adhesive only to base structure 154, instead of outer cover 14.In this manner, web sausage 22 is formed as shown in FIG. 15. Websausage 22 then advances along the direction shown by arrow 242 toanother work station. Other possible work stations include waist pieceapplicators or the like.

Web sausage 22 eventually is cut into absorbent articles 35. Thiscutting can be done by any of a variety of well known cutting machines.For example, a final cut-off roll (not shown) having a knife (not shown)extending across the roll, in combination with an anvil roll (not shown)can sever web sausage 22. Absorbent articles 35 severed from web sausage22 are transferred by conveyor to a stacker (not shown).

As suggested in FIG. 12 at and adjacent the 15—15 cross-sectionindication, each absorbent article 35, when separated from web sausage22, includes a front portion and a back portion, and a crotch portionbetween the front portion and the back portion. The 15—15 cross-sectionis taken at the crotch portion whereby FIG. 15 represents across-section of the crotch portion of a respective such absorbentarticle.

Elastomeric elements 54 preferably comprise continuous strands, ribbons,or one or more layers of a polymeric and/or elastomeric material, suchas a rubber material, which is adhered to substrate portions 50A, 50B ina stretched condition. Elastomeric elements 54 can also comprisematerials set forth with respect to leg cuff pieces 80 in the firstembodiment of the invention. A first pair of sets of elastomericelements 54CF, as shown in FIG. 15, are located at respective outwardedges of base structure 154. Elastomeric elements 54CF can provide theelastic properties of containment flaps 98 by moving flaps 98 away fromabsorbent article 35 and into contact with a user's body.

Leg cuffs 100 ensure proper fitting of absorbent article 35 to a user'sbody. A second pair of sets of elastomeric elements 54LC, locatedinwardly from the outward edges of base structure 154, provide elasticproperties of leg cuffs 100. As shown in FIG. 15, leg cuffs 100 arepreferably formed by ribbons or strands 54LC along the lower inwardportion of substrate portions 50A, 50B. These ribbons or strands 54LCare only glued or otherwise secured to base structure 154 in areas whichwill be near leg cut-outs 30 in the assembled absorbent article 35.

Elastomeric elements 54CF for containment flaps 98 preferably arestretched to a higher percentage of their stretch-to-stop distance thanelastomeric elements 54LC which elasticize leg cuffs 100, whereby thecontainment flaps 98 extend outwardly toward the user's body. While twoelastomeric elements 54CF are shown for containment flaps 98 and fourelastomeric elements 54LC are shown for leg cuffs 100, any number of therespective elastomeric elements can be used for the containment flaps orthe leg cuffs.

The various paths and sections of absorbent article assembly system 8 inFIG. 12 operate simultaneously at controlled speeds to form absorbentarticles. The various devices can be controlled by a central controller(not shown), such as a digital or analog control system to ensure properoperation and timing for each device in each material operating path.

Furthermore, the devices can be modified as appropriate. For instance,ultrasonic bonders 120, 162, and 228 can be replaced with other knownbonding devices utilizing gluing, stitching or any other well knownmethod of securing elements.

Those skilled in the art will now see that certain modifications can bemade to the invention herein disclosed with respect to the illustratedembodiments, without departing from the spirit of the instant invention.And while the invention has been described above with respect to thepreferred embodiments, it will be understood that the invention isadapted to numerous rearrangements, modifications, and alterations, allsuch arrangements, modifications, and alterations are intended to bewithin the scope of the appended claims.

To the extent the following claims use means plus function language, itis not meant to include there, or in the instant specification, anythingnot structurally equivalent to what is shown in the embodimentsdisclosed in the specification.

What is claimed is:
 1. A method of making an absorbent article, themethod comprising: (a) securing a first pair of outwardly-disposedelastomeric elements to a first elongate substrate having a lengthdimension and a width dimension, and securing, to the first elongatesubstrate, a second pair of elastomeric elements, between the first pairof elastomeric elements, the first and second pairs of elastomericelements being aligned with the length dimension, and spacedtransversely from each other across the width dimension of the firstelongate substrate; (b) securing the first elongate substrate to asecond substrate, with the first and second pairs of elastomericelements disposed between the second substrate and the first elongatesubstrate to form a base structure having a main body extending alongthe length dimension, opposing outside edge portions, and opposingoutside edges on the outside edge portions; (c) securing an absorbentcore and a bodyside liner to the base structure; and (d) securing anouter cover to the base structure such that the base structure isbetween the outer cover and the bodyside liner, thereby making anabsorbent article wherein the first pair of elastomeric elementsprovides containment flap elastomeric elements for the absorbent articleand the second pair of elastomeric elements provides leg cuffelastomeric elements.
 2. A method as in claim 1, the method includingthe steps of folding outside edges of the base structure inwardly into aJ-shape and bonding the opposing outside edges to inwardly disposedportions of the base structure to maintain the J-shape.
 3. A method asin claim 2, the method including the step of subsequently severing thefirst and second pairs of elastomeric elements.
 4. A method as in claim1, including the steps of applying adhesive to at least one of a surgelayer and a corresponding area of the bodyside liner, severing the surgelayer, and securing the surge layer to the bodyside liner such that thesurge layer is positioned between the bodyside liner and a side of theabsorbent core which will be disposed toward a body of a wearer of theabsorbent article.
 5. A method as in claim 1, including the steps ofcutting absorbent core material to form the absorbent core, and foldingthe bodyside liner around at least a portion of the absorbent corebefore securing the bodyside liner to the base structure.
 6. A method asin claim 1, including the steps of drawing the base structure through afirst nip at a first speed, then drawing the base structure through asecond nip, rolls of the second nip operating at a second speed slowerthan the first speed, thereby forming ruffles in the base structurebetween the first and second nips, the second nip securing the bodysideliner and absorbent core to the base structure.
 7. A method as in claim1, including the step of securing ears to the cuter cover before cuttingleg cut-outs from the outer cover.
 8. A method as in claim 1, including,after step (b), the step of crushing and sufficiently weakening so as tosever the first and second pairs of elastomeric elements without cuttingand damaging the first or second substrate.
 9. A method of making anabsorbent article, the method comprising: (a) securing together firstand second elongate substrates having aligned respective first andsecond length dimensions, with a first pair of outwardly-disposedcontainment flap elastomeric elements between the first and secondelongate substrates, and a second pair of leg cuff elastomeric elementspositioned between, and laterally spaced from, the containment flapelastomeric elements, and between the first and second elongatesubstrates, thereby forming a base structure; (b) securing an absorbentcore to a bodyside liner to make a bodyside liner-absorbent corecombination; (c) securing the base structure to the bodysideliner-absorbent core combination to form an absorbent subassembly suchthat the absorbent core is enclosed between the bodyside liner and thebase structure; and (d) securing an outer cover to the absorbentsubassembly.
 10. A method as in claim 9 including orienting theabsorbent subassembly with respect to the outer cover such that the basestructure is between the outer cover and the bodyside liner.
 11. Amethod as in claim 9, including sizing and positioning the basestructure relative to the bodyside liner such that the base structureextends outwardly from lateral edges of the bodyside liner.
 12. A methodas in claim 9, the base structure having a main body extending along atleast one of the first and second length dimensions, opposing outsideedge portions, and opposing outside edges on the outside edge portions,the method including folding the outside edges of the base structureinwardly into a J-shape and bonding the outside edges to inwardlydisposed portions of the base structure.
 13. A method as in claim 9,including folding opposing edge portions of the base structure inwardlyand downwardly around the absorbent core to form containment flaps, andbonding the base structure to itself so as to retain the containmentflaps in the desired inwardly folded orientation.
 14. A method as inclaim 9, including the steps of cutting absorbent core material to formthe absorbent core, and folding the bodyside liner around at least aportion of the absorbent core before securing the bodyside liner to thebase structure.
 15. A method as in claim 9, including the steps ofdrawing the base structure through a first nip at a first speed, thendrawing the base structure through a second nip, rolls of the second nipoperating at a second speed slower that the first speed, thereby formingruffles in the base structure between the first and second nips, thesecond nip securing the bodyside liner and absorbent core to the basestructure.
 16. A method as in claim 9, including, after step (a), andwith the first and second pairs of elastomeric elements disposed betweenthe first and second elongate substrates, the step of severing the firstand second pairs of elastomeric elements without damaging the first orsecond elongate substrates.
 17. A method as in claim 9, the firstelongate substrate comprising first and second substrate portions spacedfrom each other along the first length dimension, and secured to thesecond elongate substrate along opposing side portions of the secondelongate substrate.